Groove-forming pattern assembly for a concrete wall form structure

ABSTRACT

A two-piece groove-forming pattern assembly adapted for use in connection with a concrete wall form structure and including a base piece adapted to be nailed in position on the form structure, and a pattern piece adapted to be applied to the thus positioned base piece by a snap-on operation.

Patnted Aug. 28,

GROOVE-FORMING PATTERN ASSEMBLY FOR A CONCRETE WALL FORM STRUCTURE The improved two-piece pattern assembly comprising the present invention is designed for use primarily in connection with a concrete wall form structure where it is desired that the finished concrete wall resulting from use of the form structure shall have formed therein a vertical, horizontal or other directional groove, the groove being either of a functional nature as, for example, to provide anchoring means for a wall facing or for decorative purposes. The invention is, however, capable of other uses and a pattern assembly embodying the principles of the invention may, if desired and with or without modification as required, be employed as a masonry crevice-forming device for reglet attachment, or as a paving or other template-type structure where adjacent concrete pourings are to be interlocked by a key and a cooperating and complemental keyway. Irrespective, however, of the particular use to which the present invention may be put, the essential features thereof are at all times preserved.

The present invention is found to be especially useful in connection-with a concrete wall form which employs Steel-Ply wall form panels such as are shown, for example, in US. Pat. No. 2,997,769, granted on Aug. 29, 1961 and entitled TIE ROD ASSEMBLY FOR CON- CRETE WALL FORMS, and in US. Pat. No. 2,640,249, granted on June 2, 1953 and entitled WALL FORM PANEL." Concrete wall form panels of this general type are manufactured and sold by Symons Corporation of Des Plaines, Ill. and consist of rectangular plywood facings which are bounded by marginal, rectangular, steel, reinforcing frames. Such Steel-Ply panels are generally in the form of shallow tray-like structures, the bottoms of which are the plywood facings and the side and end portions of which are in the form of marginal steel frame members. The panels are set up or erected in edge-to-edge relationship with adjacent frame side members abutting each other along seam lines. Two series of such erected panels which are maintained in spaced apart relationship by way of horizontally extending combined tie and spreader rods or bars define front and rear form sides between which wet concrete is poured in the formation of a concrete wall.

When a concrete wall form which consists of Steel- Ply panels and is erected as briefly outlined above is stripped from the hardened concrete wall and then dismantled, the aforementioned seam lines which exist at the junctureregion between adjacent panels leave corresponding ridges on the side surfaces of the wall. Where a contoured concrete wall is to be provided with vertical or horizontal grooves, or both, and where Steel-Ply panels are used, it has been found that by predeterminingthe location of the contour grooves in the finished wall so that they match the locations of the seam lines between adjacent Steel-Ply wall panels, the problem of seam-like ridges in the side surfaces of the finished concrete wall can be eliminated altogether. Accordingly, and as contemplated by the present invention, a two-piece pattern assembly is provided and it consists of a base piece which is of sufficient width that it overhangs the exposed metal surfaces of two adjacent frame side members and thus, overlaps the adjacent side marginal regions of the two adjacent plywood panel facings in a concrete wall form structure. By reason of its overlap with the plywood on opposite sides of the abutting or adjacent frame side members, the side members may conveniently be stapled directly to said adjacent side marginal regions of the plywood facings at appropriate points along its longitudinal extent. When the base piece is thus in place on the wall form structure, a pattern piece which is appropriately shaped to the contour of the groove to be formed in the concrete wall side surface, is applied to the stapled base piece by a snap-0n operation so that it bridges the juncture region between the two adjacent frame side members as well as the side members themselves and affords a pattern for leaving the desired groove in the adjacent side surface of the finished concrete wall.

Preferably, both pieces of the groove-forming pattern assembly are formed of a plastic material having suffcient rigidity to withstand the pressure of the poured wet concrete, but nevertheless, sufficiently penetrable that it is susceptible to a stapling operation when the base piece is applied to the form structure. The use of sheet metal is, however, contemplated and, in such an instance, the base piece will be nailed in position, suitable preformed nail holes being provided to accommodate the nailing process. I I

The provision of a groove-forming pattern assembly such as has briefly been outlined above constitutes the principal object of thepresent invention. Other objects of the invention, not at this time enumerated, will become readily apparent as the following description ensues. I

The invention consists in the several novel features which are hereinafter set forth and are more particularly defined by the claims at the conclusion hereof.

In the accompanying single sheet of drawings forming a part of this specification, two illustrative embodiments of the invention are shown.

In these drawings:

FIG. 1 is a fragmentary perspective view of a portion of a concrete wall form structure, showing two twopiece groove-forming pattern assemblies embodying the preferred form of the present invention operatively installed thereon;

FIG. 2 is an enlarged fragmentary exploded perspective view of one of the pattern assemblies of FIG. 1;

FIG. 3 is an enlarged fragmentary horizontal sectional view taken on the horizontal plane indicated by the line 33 of FIG. 1 and in the'direction of the arrows;

FIG. 4 is a fragmentary exploded perspective view similar to FIG. 2 but showing a modified or alternate form of a two-piece groove-forming pattern assembly embodying the invention; and

FIG. 5 is a sectional view, similar toFIG. 3, but showing the modified form of pattern assembly of FIG. 4.

Referring now to the drawings in detail and in particular to FIGS. 1 to 3, inclusive, afragmentary portion of a prefabricated concrete wall form structure is illistrated therein and is designated in its entirety by the reference numeral 10. Such concrete wall form structure is made up of an upstanding front side 12 and a parallel rear side 14. The two sides are spaced apart and are adapted, as well understood in the art, to have wet concrete poured therebetween for wall-forming purposes. Each side consists of a horizontal series of rectangular panels 16 which are disposed in edge-toedge relationship, only four such panels being disclosed in the drawings hereof. The panels 16 of the two form sides are maintained in spaced apart parallel relationship by means of conventional combined tie rod and spreader devices, one of which is identified by the reference numeral 18. The individual panels are of the prefabricated type that is known as Steel-Ply as heretofore set forth. Each concrete wall form panel 16 consists of a rectangular plywood facing 20 having fixedly applied thereto studding in the form ofa marginal reinforcing frame of steel or other metal, such frame consisting of vertical side members 22 and horizontal end members 24. Each vertical side members of the reinforcing frames of the panels 16 is in the form of a structural metallic bar which is generally of shallow U-shape cross section and comprises spaced, marginal, outwardly extending, parallel ribs 26 and 28 and a connecting base or web portion 30. On each web portion is a shallow, inwardly and longitudinally extending rib 32 which defines a recess 34, the purpose of which is to receive the adjacent vertical edge region of the associated plywood facing 20.

At vertically spaced regions along the vertical side members 22 of the reinforcing frames, the ribs 26 and 28 are provided with registering notches 36 in order to accommodate the slotted ends of the combined tie rod and spreader devices 18, while the web portions 30 of the vertical marginal frame members 22 are formed with rectangular slots or openings 38 which are in horizontal register with the notches 36 and are adapted to receive therethrough the bolts of conventional connecting bolt and wedge assemblies 40 by means of which adjacent panels are clamped together in edge-toedge relation. The horizontal end members 24 of the reinforcing frames are similar in design and construction to the vertical side members 22 and corresponding reference numerals are applied to the corresponding parts thereof.

The arrangement of parts thus far described is purely conventional and no claim is made herein to any novelty associated with the same, the novelty of the present invention residing rather in the construction, combination and arrangement of parts of the two illustrated types or forms of groove-forming pattern assemblies which will now be described in detail and subsequently claimed.

Considering now the form of the invention which is illustrated in FIGS. 1 to 3, inclusive, each of the two groove-forming pattern assemblies of FIG. 1 of the drawings is designated in its entirety by the reference numeral 50 and is comprised of two component parts, namely, a base strip 52 and a counterpart pattern strip 54, the two parts, when assembled on each other, defining a tubular structure. As will be described in greater deail, the base strip 52 is of elongated ribbon-like design and is adapted to be stapled to a pair of adjacent wall form panels 16 in such a manner as to cover not only the seam line which exists between the abutting vertical side members 22 of the facing reinforcing frames of the panels, but also completely to cover the surface portions of such frames which normally remain exposed on the inner side of the form structure where the wet concrete is to be poured. As will also be described more specifically presently, the pattern strip 54 of each pattern assembly 50 is separately formed from the base strip 52, is commensurate in length with the latter, and is adapted to be releasably secured thereto by a press-on snap action. When the pattern strip 54 is in place on the base strip 52, the pattern assembly presents a generally trapezoidal cross section with the base of the trapezoid resting on the inside surface of the associated wall form side to which the assembly is applied and in covering relationship with respect to the exposed metal surfaces of the adjacent side members 28 of the reinforcing frames. Both the base strip 52 and the pattern strip 54 are readily adaptable to a conventional extrusion operation in the manufacture thereof, utilizing conventional extrusion apparatus and methods, this being the case regardless whether the strips are formed of a suitable moldable plastic material or a metal such as aluminum. Preferably, the two strips 52 and 54 are formed of a suitable thermoplastic plastic material or a thermosetting plastic material which offers the advantage that the base strip 52 may be stapled in position on the form without regard to the formation of staple-receiving or nail-receiving holes therein, as will be described presently.

As best illustrated in H05. 2 and 3 of the drawings, the base strip 52 of each pattern assembly 50 is generally of T-shape in cross section, the strip being of elongated design and embodying a relatively thick, centrally disposed, outwardly extending, integral leg flange 56 and, in addition, a pair of oppositely extending, integral, coplanar head flanges 58. The distal edge portion of the leg flange 56 is formed with a generally semicylindrical, bulbous and enlarged rib 62 which constitutes a reaction anchor for a portion of the pattern strip 54 when the latter is assembled on the base strip 52. The two coplanar head flanges 58 are of equal width and each is formed along its distal edge with an enlarged rib 64 which is preferably polygonal in transverse cross section as clearly shown in FIG. 3. The two ribs 64 of the head flanges 58 of the base strip 52 likewise constitute reaction anchors for other portions of the pattern strip 54 as will be described subsequently.

in order to apply the base strip 52 to the wall form structure 10, the juncture region between the leg and head flanges of said base strip is brought into register and alignment with the vertical seam line which exists at the juncture between the abutting and adjacent side members 26 of the panel reinforcing frames and, thereafter, staples such as are indicated at 66 are forcibly driven through the leg flanges and into those portions of the plywood facings 20 that are on opposite sides of the abutting and adjacent side members 28 in order to draw the outer face of the strip against said plywood panels, care being taken in the placement of the stapling tool to avoid contact of the staples with said side members.

It is to be noted at this point that after the base strip 52 has been applied to the wall form in the manner set forth above, the strip rests against the adjacent wall form side 12 or 14, as the case may be, along two vertical lines which are established by the enlarged ribs 64, the medial regions of the coplanar flanges 58 and 60, considered collectively, remaining slightly spaced from the plane of the inside face of such form side.

The pattern strip 54 which constitutes a counterpart of the base strip 52 is generally of channel design and includes a pair of outwardly diverging side flanges 70 which are connected together along their proximate edges by an integral bight portion 72. The central part of the bight portion 72 presents an internal cap channel 74 which is defined by curved retainer flanges 75 that are adapted to straddle the enlarged rib 62 on the distal edge portion of the leg flange 56 of the base strip 52 when the two strips 52 and 54 are assembled by snapping them together. The cap channel 14 is'formed with a flared entrance throat which exists by reason of outturned channel edges 76. The latter extend along the outer edges of the retaining flanges 75. The outer edges of the outwardly diverging side flanges 70 are formed with inwardly facing troughs 78 which are adapted to receive therein the enlarged ribs 64 of the distal edge portions of coplanar head flanges 58 of the base strip 52 when the strips 52 and 54 are in assembled relation.

It will be understood, of course, that when the base strip 52 and the pattern strip 54 are initially cut to length, appropriately positioned slots or openings 80 and 82 will be formed through the strips 52 and 54, respectively, in order to accommodate passage of the combined tie rod and spreader devices 18 through the strips at the time of final assembly of the wall form. In the case of the base strip 52, the slot 80 passes through one of the leg flanges 56 thereof. The number of slots 80, 82 which are formed in the strips 52 and 54 will depend, of course, upon the number of combined tie rod and spreader devices which are used. To avoid passing the slot 80 through the leg flange 56 of the base strip 52, it is contemplated that, if desired, the slot 80 will be laterally offset from the position in which it is shown in FIG. I in order that the associated combined tie rod and spreader device 18 may pass alongside said leg flange 56. In such an instance, the slot 82 in the bight portion 72 will be commensurately laterally offset and the entire pattern assembly 50 will be shifted sidewise so that these slots will register with the juncture region between adjacent panels.

The groove-forming pattern assembly 50 is designed for use in a concrete wall form structure where relatively high concrete pressures are involved during concrete-pouring operations. In a given structure, after the base strip 52 has been applied to the selected form side in the manner heretofore set forth, the pattern strip 54 is mounted'on the base strip by orienting the pattern strip with respect to the stapled base strip so that the two strips assume the positions in which they are shown in FIG. 2, after which the pattern strip is moved forwardly toward the base strip until the side flanges 75 of the cap channel 74 engage and encompass the enlarged rib 62 on the distal portion of the leg flange 50 of the base strip 52, while substantially at the same time the inwardly facing troughs 78 nearthe outer side edges of the outwardly diverging side flanges 70 of the pattern strip 54 snap into position over the enlarged ribs 64 on the distal edges of the head flanges 58 of the base strip 52. With the pattern strip 54 thus assembled on the base strip 52, concrete-pouring operations may be resorted to.

Insofar as assembly of the pattern strip 54 on the base strip 52 is concerned, if the strips are of relatively short length, the pattern strip may be pushed onto the base strip by a single pushing operation wherein the former strip is moved bodily horizontally so that it snaps into position on the latter strip by a coextensive detent action or latching operation. Where relatively long strips are concerned, application of the pattern strip 54 to the base strip 52 may be accomplished by a progressive latching operation wherein a localized region of the pattern strip is initially pushed onto the base strip and, thereafter, by running the hand longitudinally along the pattern strip with a moderate degree of forward pressure, progressive movement of the pattern strip to its final installed position'will result.

It will be understood that the plastic or other material from which the two strips are formed is possessed of a relatively high degree of resiliency so that after the pattern strip 54 is assembled on the base strip 52, it will remain securely in position thereon against dislodgment until the same is forcibly pulled therefrom for purposes of dismantling the concrete wall form structure 10 and reclaiming the strips for a subsequent use. At the time the form structure is stripped from the hardened concrete wall and the panels 16 are moved away from the wall, the assembled strips 54 and 52 remain intact on the adjacent panels. To remove the strips for reuse or salvage purposes, the pattern strip may be forcibly pulled from the base strip by a reversal of the process which was followed in installing it, whether immediate or progressive as described above, after which withdrawal of the staples 66 from the plywood panel facings 20 will release the two adjacent panels from each other. It will be understood, of course, that at the time the panels 16 are removed from the concrete wall, the pattern strip 54 will leave a commensurate groove in the adjacent side face of the hardened concrete wall. Although the plastic material which is used in extruding the strips 54 and 52 possesses adequate resiliency to allow for the aforementioned snap-on action during assembly of the two strips, the pattern strip 54 is possessed of adequate rigidity to withstand the pressure of the wet poured concrete without any appreciable degree of collapse, distortion or deformation. The region of the pattern strip 54 which normally would be most susceptible to deformation due to inward pressure on the strip by the wet concrete is the centerline region of the bight portion 72. However, this region is firmly reinforced by the relatively thick leg flange 52 of the T- shaped base strip 52.

In FIGS. 4 and 5 of the drawings, a slightly modified form of groove-forming pattern assembly is shown. In this form of the invention, the base strip 252, instead of being T-shape in cross section, is generally in the form of a flat strip of plastic material, the leg flange 56 being omitted. Additionally, certain other shape characteristics of both the base strip 252 and the pattern strip 254 render these two strips different from the strips 52 and 54, not only in shape but also in function as will be described presently. In view of the similarity between the previously described fonn of the invention and the form of FIGS. 4 and 5, and in order to avoid needless repetition of description, similar reference numerals but of a higher order have been applied to the corresponding parts as between the disclosures of FIGS. 4 and 5 and FIGS. 1, 2, and 3.

In addition to the omission of the leg flange 56, the base strip 252 of the alternate form of the invention is of generally flat ribbon-like configuration and is provided with a series of closely spaced, V-shaped ribs or serrations 281 on the face thereof which opposes the concrete wall form side to which it is applied. These ribs or serrations are adapted to bear against the wall form side when the base strip 252 is stapled in position thereon. In place of the enlarged ribs 64 on the coplanar head flanges 58 of the base strip of the pattern assembly 50 of FIGS. 1, 2, and 3, the outer or distal edge regions of the outwardly diverging side flanges 270 of the pattern strip 254 of the pattern assembly 250 of FIGS. 4 and 5 are formed with flexible tapered lip seals 283, each of which establishes an inwardly facing heellike shoulder 285 which is designed for interlocking latching engagement with an outturned similarly ta pered flange 287 on the adjacent side edge of the base strip 252. A further difference between the pattern strip 254 and the pattern strip 54 resides in the provision of thickened regions 289 at the juncture regions between the side flanges 270 and the bight portion 272. Otherwise, the strips 252 and 254 remain substantially the same as the strips 52 and 54.

The manner of application of the pattern strip 254 to the previously stapled base strip 252 remains substantially the same as the manner of application of the pattern strip 54 to the base strip 52 and, therefore, it need not be described in detail. However, the manner in which the two strips function or cooperate with each other during such application is somewhat different. It is to be noted that the lip seals 283 present forwardly or outwardly facing flat surfaces 290 which, as shown in FIG. 4, oppose similar rearwardly or inwardly facing flat surfaces 292 on the flanges 287 of the base strip 252 when the two strips 254 and 252 are juxtapositioned preparatory to pushing the same together. Thus, when the pattern strip 254 is moved toward the base strip 252 for interlocking purposes, a camming action between these two surfaces 290 and the two surfaces 292 takes place and, as a consequence, the side flanges 270 of the channebshaped pattern strip 254 are spread apart slightly until such time as the tapered lip seals 283 snap behind the tapered flanges 287 to provide an effective interlock between the two strips. At this time, the feather edges of the lip seals 282 come to rest on the plywood facings 220 of the contiguous panels 216, thus precluding the entrance of concrete behind the pattern strip 254, as well as the base strip 252.

It will be understood that in constructing and using either of the herein described groove-forming pattern assemblies 50 and 250, the base strip and the coacting pattern strip will be cut from the extruded plastic stock to equal lengths, such lengths being determined by the span of the wall form surface which is to be covered. if vertical grooves or keyways are to be provided in the finished concrete wall or other concrete structure, long strips may be provided which bridge over successive tiers of horizontally aligned concrete wall form panels. Similarly, if horizontal grooves or keyways are desired, the long strips may bridge over successive rows of vertically aligned panels. Checkerboard piecing of short unit length strips so that the joints between converging strips overlie the quadrilateral juncture regions between any group of four panels may be resorted to if desired. In such an instance, intersecting grooves in the completed concrete wall will result.

It is also to be noted that after two counterpart strips and of equal length are provided and installed on the concrete wall form structure 10 if immediately after application of the pattern strip to the base strip has been completed, it is found that pattern strip placement has been performed in such a manner that either end thereof slightly overlaps the adjacent end of the base strip, the pattern strip may be slid lengthwise on the base strip to correct the error and thus bring the two strips into perfect register.

The invention is not to be limited to the exact arrangement of parts shown in the accompanying drawings or described in this specification as various changes in the details of construction may be resorted to without departing from the spirit or scope of the invention. For example, although the present grooveforming pattern assemblies 50 and 250 are shown and described herein as being positioned over the juncture region between two adjacent Steel-Ply" panels, such assemblies may, if desired, be employed in connection with other types of form panels. Furthermore, it is not essential that these assemblies be positioned along the juncture regions of adjacent panels. If desired, they may extend across the face of one or more panels at any selected region or regions thereof. Therefore, only insofar as the invention is particularly pointed out in the accompanying claims is the same to be limited.

Having described the invention what I claim as new and desire to secure by letters patent is:

1. In a concrete wall form structure, in combination, opposed wall form sides each of which presents an inside planar surface including at least one facing and against which wet concrete is adapted to be poured in the formation ofa wall, and a composite two-piece grove-forming pattern assembly supported on one of said surfaces and being adapted to be removed bodily from the assembly formed groove when the wall form structure is stripped from the hardened concrete wall, said pattern assembly including an elongated ribbonlike base strip which is T-shape in transverse cross section and has its rear face connected to said one surface, and a separately-formed pattern strip coextensive with said base strip, said pattern strip being arched transversely so as to provide diverging side flanges and a connecting bight portion, and interlocking means on the side edges of said base strip and the distal edges of said side flanges of the pattern strip for removably securing said pattern strip in coextensive relationship on thebase strip so as to define, in combination therewith, a tubular structure, said base strip including a longitudinally extending leg flange which projects centrally and transversely across the tubular structure and bears at its distal edge against the central region of said flat planar bight portion, and said bight portion is provided with integrally formed longitudinally extending channel-forming retaining flanges which straddle the distal edge region of said leg flange and confines the same therebetween.

2. In a concrete wall form, the combination set forth in claim 1 and wherein the distal edge region of said leg flange is formed with an enlarged longitudinally extending bulbous rib and the channel-forming retaining flanges on said connecting bight portion are curved in conformity with the curvature of the bulbous rib.

3. In a concrete wall form, the combination set forth in claim 2 and wherein the channel-forming retaining flanges on said connecting bight portion are formed with outturned channel edges to facilitate reception of the bulbous rib within the channel which is formed by said retaining flanges. 

1. In a concrete wall form structure, in combination, opposed wall form sides each of which presents an inside planar surface including at least one facing and against which wet concrete is adapted to be poured in the formation of a wall, and a composite two-piece grove-forming pattern assembly supported on one of said surfaces and being adapted to be removed bodily from the assembly formed groove when the wall form structure is stripped from the hardened concrete wall, said pattern assembly including an elongated ribbon-like base strip which is T-shape in transverse cross section and has its rear face connected to said one surface, and a separately-formed pattern strip coextensive with said base strip, said pattern strip being arched transversely so as to provide diverging side flanges and a connecting bight portion, and interlocking means on the side edges of said base strip and the distal edges of said side flanges of the pattern strip for removably securing said pattern strip in coextensive relationship on the base strip so as to define, in combination therewith, a tubular structure, said base strip including a longitudinally extending leg flange which projects centrally and transversely across The tubular structure and bears at its distal edge against the central region of said flat planar bight portion, and said bight portion is provided with integrally formed longitudinally extending channel-forming retaining flanges which straddle the distal edge region of said leg flange and confines the same therebetween.
 2. In a concrete wall form, the combination set forth in claim 1 and wherein the distal edge region of said leg flange is formed with an enlarged longitudinally extending bulbous rib and the channel-forming retaining flanges on said connecting bight portion are curved in conformity with the curvature of the bulbous rib.
 3. In a concrete wall form, the combination set forth in claim 2 and wherein the channel-forming retaining flanges on said connecting bight portion are formed with outturned channel edges to facilitate reception of the bulbous rib within the channel which is formed by said retaining flanges. 